Omega Products CSPID1 Installation Manual

1
DEDICATED SINGLE AND DUAL PID MODULES FOR THE
MODULAR CONTROLLER SERIES
HOT-SWAPPABLE REPLACEMENT REDUCES DOWNTIMEAUTO ADDRESSING MINIMIZES CONFIGURATION TIMEFULLY ISOLATED DESIGN PROVIDES RELIABLE OPERATIONPID CONTROL WITH REDUCED OVERSHOOTUNIVERSAL INPUTS ACCEPT TC, RTD, 0-10 V and 0/4-20 mA
ON DEMAND AUTO-TUNING OF PID SETTINGSDC ANALOG OUTPUT (OPTIONAL, CSPID1 ONLY)HEATER CURRENT INPUT (OPTIONAL) ENSURES DETECTION
OF HEATER CIRCUIT FAILURE
WINDOWS
®
CONFIGURATION SOFTWARE
GENERAL DESCRIPTION
The Model CSPID series modules are full featured PID controllers designed for use with the Modular Controller Series. The CSPID1 is a single loop controller, while the CSPID2 is a dual loop controller. The design of the system provides a true modular PID control platform for multi-zone control applications. The modules can accept a wide range of thermocouple, RTD, 0-10 V, 0/4-20 mA signals. With multiple discrete outputs, plus an optional analog output (CSPID1 only), the CSPID modules can perform virtually any combination of time-proportioning or linear control for heat, cool, or heat/cool applications. The discrete outputs may also be assigned to one of seven internal soft alarms. The CSPID1’s optional linear output can be assigned to transmit virtually any internal variable.
The CSPID modules connect and communicate via a backplane connection to the CSMSTR Modular Controller Series Master. The CSMSTR, equipped with serial ports as well as an Ethernet port, allows the system to share data with PCs, PLCs, and SCADA systems. The Master supports any combination of up to 16 CS Series modules.
The CSPID modules are available with various discrete output combinations, including relays, open drain MOSFETs, and triac outputs. For applications requiring large loads to be controlled, several DIN rail mount relays are available.
The modules can operate in On/Off, P, PI, or PID control mode, and use an on-demand Auto-Tune that establishes the tuning constants. The PID constants may be fine-tuned through the serial or Ethernet interface. The modules employ a unique overshoot suppression feature, which allows the quickest response without excessive overshoot. The modules can also be operated in manual mode, providing the operator with direct control of the output.
Internal power management circuits allow the modules to be replaced while power is applied, which reduces downtime in the event of a relay failure. All configuration information is stored locally within each module, as well as in the Master, so replacement modules do not need to be configured.
The Modular Controller Series’ high density packaging and DIN rail mounting saves time and panel space. The backplane connection provides power and communication to the module and snaps easily onto standard top hat (T) profile DIN rail.
CONFIGURATION
The Modular Controller Series is configured with Windows®compatible Crimson®software. The software is an easy to use, graphical interface which provides a means of communication configuration, as well as commissioning and calibration of new systems.
ALARMS
Each loop within the modules has seven internal “soft” alarms, which can be assigned to trigger any output. This includes four process alarms, two heater current, and one input fault alarm.
ANALOG OUTPUT OPTION (CSPID1 ONLY)
The optional DC Analog Output (10 V or 20 mA) can be independently configured and scaled for control or re-transmission purposes.
HEATER CURRENT MONITOR OPTION
The optional Heater Current Monitor input is useful for early warning of heater degradation, or heater circuit failure. The input connects to a current transformer with an output of 100 mAAC to ensure that proper heater current is present when the control output is on, and that little or no current is present when the output is off. This option provides immediate warning of a circuit short or open, instead of waiting for a high or low temperature shutdown alarm.
MODEL CSPID – MODULAR CONTROLLER SERIES PID MODULES
Bulletin No. CSPID1-F Drawing No. LP0542 Released 03/09
Tel +1 (717) 767-6511 Fax +1 (717) 764-0839 www.redlion.net
DIMENSIONS In inches (mm)
CAUTION: Risk of Danger.
Read complete instructions prior to
installation and operation of the unit.
CAUTION: Risk of electric shock.
C
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SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in the manual or on equipment must be observed to ensure personal safety and to prevent damage to either the instrument or equipment connected to it. If equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
Do not use the controller to directly command motors, valves, or other actuators not equipped with safeguards. To do so can be potentially harmful to persons or equipment in the event of a fault to the controller. An independent and redundant temperature limit indicator with alarm outputs is strongly recommended.
SPECIFICATIONS
1. POWER: Derived from system backplane. (CSPID1 draws 150 mA max. load
on power input of MASTER, CSPID2 draws 125 mA max). Modules may be
hot-swapped (Replaced while powered up).
2. LEDs*:
STS - Status LED shows module condition OP1, OP2, OP3, OP4 - Indicate status of outputs 1, 2, 3, and 4 ALM, or AL1 and AL2 - Alarm LEDs are lit during any internal alarm
condition * Default configuration.
3. MEMORY: Non-volatile memory retains all programmable parameters.
MASTER also stores the parameters in order to reprogram modules that are
replaced.
4. INPUT:
GENERAL:
Sample Time: 67 msec (15 Hz) Common Mode Rejection: >110 dB, 50/60 Hz Normal Mode Rejection: >40 dB, 50/60 Hz Temperature Coefficient: 0.01%/°C Step Response Time: 200 msec typ., 250 msec max
THERMOCOUPLE INPUTS:
Types: T, E, J, K, R, S, B, N, C Input Impedance: 20 M Ω Lead Resistance Effect: 0.25 µV/Ω Cold Junction Compensation: Less than ±1°C typical (±1.5°C max) over 0
to 50 °C ambient temperature
Resolution: 0.1°
RTD INPUTS:
Type: 2 or 3 wire Excitation: 150 µA Lead Resistance: 15 Ω Max Resolution: 1 or 0.1°
PROCESS INPUT:
5. TEMPERATURE INDICATION ACCURACY: ± (0.3% of span, +1°C).
Includes NIST conformity, cold junction effect, A/D conversion errors, temperature coefficient and linearization conformity at 23 °C after 20 minute warm up.
6. ISOLATION LEVEL: 500 Vrms @ 50/60 Hz for 1 minute between the
following:
OP1 OP2 OP3 OP4 Linear Output (CSPID1 only) Signal Inputs and HCM CS Master Power Supply Input
7. COMMUNICATIONS: Provided by the CS Master
8. A/D CONVERTER: 16 bit resolution
9. DISCRETE OUTPUTS: CSPID1: Outputs 1 and 2 available as Solid State NFET, Form A relay or
Triac. Output 3 is a Form C relay.
CSPID2: Outputs 1 through 4 available as Form A relay, Solid State NFET,
or Triac.
Solid State Output:
Type: Switched DC, N Channel open drain MOSFET Current Rating: 1 Amax VDS ON: 0.3 V @ 1 A VDS MAX: 30 VDC Offstate Leakage Current: 0.5 mA max
Form A Relay Output:
Type: N.O. Current Rating: 3 Amps @ 125 VAC
1/10 HP @ 125 VAC
Life Expectancy: 200,000 cycles at maximum load rating. (Decreasing
load, increasing cycle time, and use of surge suppression such as RC snubbers increases life expectancy.)
Form C Relay Output:
Type: SPDT Current Rating: 5 Amps @ 125 VAC or 28 VDC (resistive load)
1/8 HP @ 125 VAC
Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing
load, increasing cycle time, and use of surge suppression such as RC snubbers increases life expectancy.)
Triac: (CSPID1TA only)
Type: Optically isolated, zero-crossing detection Rating: 120 VAC, Min: 20 VAC Max Load Current: 1.0 Aacross Operating Temperature Range Min Load Current: 5 mA Offstate Leakage Current: 1 mA Max Operating Frequency: 20 to 400 Hz Protection: Internal Transient Suppression, Fused
Triac: (CSPID2T0 and CSPID2TM only)
Type: Optically isolated, zero-crossing detection Rating: 120 VAC, Min: 20 VAC Max Load Current: 0.5A @ 25°C, 0.4A@ 50°C Min Load Current: 5 mA Offstate Leakage Current: 1 mA Max Operating Frequency: 20 to 500 Hz Protection: Internal Transient Suppression, Fused
10. CONTROL MODES: Control: On/Off, P, PI, or PID Output: Time proportioning or linear (CSPID1 only) Cycle Time: Programmable from 0.0 to 60.0 sec Auto-Tune: When selected, sets proportional band, integral time, derivative
time values, and output dampening time Probe Break Action: Programmable response Sensor Fail Response: Upscale
TYPE
MEASUREMENT
RANGE
WIRE COLOR
ANSI
BS 1843
T
-200 to +400°C
-328 to +752°F
(+) Blue
(-) Red
(+) White
(-) Blue
E
-200 to +730°C
-328 to +1346°F
(+) Violet
(-) Red
(+) Brown
(-) Blue
J
-200 to +760°C
-328 to +1400°F
(+) White
(-) Red
(+) Yellow
(-) Blue
K
-200 to +1250°C
-328 to +2282°F
(+) Yellow
(-) Red
(+) Brown
(-) Blue
R
0 to +1768°C
+32 to +3214°F
No Standard
(+) White
(-) Blue
S
0 to +1768°C
+32 to +3214°F
No Standard
(+) White
(-) Blue
B
+149 to +1820°C +300 to +3308°F
No Standard No Standard
N
-200 to +1300°C
-328 to +2372°F
(+) Orange
(-) Red
(+) Orange
(-) Blue
C
W5/W6
0 to +2315°C
+32 to +4199°F
No Standard No Standard
mV -5 mV to 56 mV N/A N/A
TYPE INPUT TYPE RANGE
385
100 Ω platinum, Alpha = .00385
-200 to +600°C
-328 to +1100°F
392
100 Ω platinum, Alpha = .003919
-200 to +600°C
-328 to +1100°F
672
120 Ω nickel, Alpha = .00672
-80 to +215°C
-112 to +419°F
INPUT RANGE
ACCURACY
(18 TO 28 °C)
IMPEDANCE
MAX CONTINUOUS
OVERLOAD
RESOLUTION
10 V 0.1% span 1 M Ohm 50 V 16 bit
20 mA 0.1% span 10 Ohm 100 mA 16 bit
3
11. ALARMS:
Modes:
Manual Absolute High Acting Absolute Low Acting Deviation High Acting Deviation Low Acting Inside Band Acting
Outside Band Acting Reset Action: Programmable; automatic or latched Standby Mode: Programmable; enable or disable Hysteresis: Programmable Sensor Fail Response: Upscale
12. ANALOG DC OUTPUT (optional, CSPID1 only):
Selectable/programmable for 0-10 VDC, 0-20 mA, or 4-20 mA Resolution:
Voltage: 500 µV
Current: 1 µA Accuracy:
0.1% of full scale (18 to 28 °C)
0.2% of full scale (0 to 50 °C) Update Time: 0.0 to 60.0 sec Compliance (for current output only): 500 Ω max. Minimum load (voltage output only): 10 KΩ min. Outputs are independently jumper selectable for either 10 V or 20 mA. The output range may be field calibrated to yield approximate 10% overrange and a small underrange (negative) signal.
13. HEATER CURRENT MONITOR INPUT (optional):
Type: Single phase, full wave monitoring of load currents Input: 100 mA max. input for use with external current transformers Input Resistance: 5 Ω Accuracy: ±3.0% full scale, 5 to 100% of range Frequency: 50 to 400 Hz Minimum output on time for break alarm: 350 msec
14. ENVIRONMENTALCONDITIONS:
Operating Temperature Range: 0 to +50 °C Storage Temperature Range: -40 to +85 °C Operating and Storage Humidity: 85% max relative humidity, non-
condensing, from 0 to +50°C
Vibration According to IEC 68-2-6: 10 to 150 Hz, 0.075 mm amplitude in
X, Y, Z direction 1 g.
Shock According to IEC 68-2-27: Operational 25 g (10g relay), 11 msec in 3
directions.
Altitude: Up to 2000 meters
15. CERTIFICA TIONS AND COMPLIANCES:
SAFETY
UL Listed, File # E302106, UL508, CSAC22.2 No. 14-M05
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment
for measurement, control, and laboratory use, Part 1.
ELECTROMAGNETIC COMPATIBILITY
Emissions and Immunity to EN 61326: 2006: Electrical Equipment for Measurement, Control and Laboratory use.
Notes:
1. Criterion A: Normal operation within specified limits.
2. Criterion B: Temporary loss of performance from which the unit self­recovers.
3. The module’s analog input and/or output signals may deviate during disturbance but self-recover when disturbance is removed.
4. Power supplied from backplane via Master Module.
16. CONSTRUCTION: Case body is burgundy high impact plastic. Installation
Category I, Pollution Degree 2.
17. CONNECTIONS: Removable wire clamp screw terminal blocks.
Wire Gage: 28-16 AWG terminal gage wire Torque: 1.96-2.23 inch/lbs (0.22-0.25 N-m)
18. MOUNTING: Snaps on to standard DIN style top hat (T) profile mounting
rails according to EN50022 -35 x 7.5 and -35 x 15.
19. WEIGHT: CSPID1: 7 oz (198.4 g)
CSPID2: 7 oz (198.4 g)
BLOCK DIAGRAM
Electrostatic discharge EN 61000-4-2 Criterion B
4 kV contact discharge 8 kV air discharge
Electromagnetic RF fields EN 61000-4-3
Criterion B
3
10 V/m
Fast transients (burst) EN 61000-4-4 Criterion B
power 2 kV
I/O signal connected to power
I/O signal
2 kV
1 kV
Surge EN 61000-4-5 Criterion B
power 1 kV L-L, 2 kV L-G
signal 1 kV
Emissions:
RF conducted interference EN 61000-4-6 Criterion A
Emissions EN 55011 Class A
3 V/rms
Immunity to Industrial Locations:
4
EMC INSTALLATION GUIDELINES
Although Red Lion Controls Products are designed with a high degree of immunity to Electromagnetic Interference (EMI), proper installation and wiring methods must be followed to ensure compatibility in each application. The type of the electrical noise, source or coupling method into a unit may be different for various installations. Cable length, routing, and shield termination are very important and can mean the difference between a successful or troublesome installation. Listed are some EMI guidelines for a successful installation in an industrial environment.
1. Aunit should be mounted in a metal enclosure, which is properly connected
to protective earth.
a. The mounting clip that connects to the DIN rail should have the DIN rail
connected to protective earth.
2. Use shielded (screened) cables for all Signal and Control inputs. The shield
(screen) pigtail connection should be made as short as possible. The
connection point for the shield depends somewhat upon the application.
Listed below are the recommended methods of connecting the shield, in
order of their effectiveness.
a. Connect the shield to earth ground (protective earth) at one end where the
unit is mounted.
b. Connect the shield to earth ground at both ends of the cable, usually when
the noise source frequency is over 1 MHz.
c. Connect the shield to common of the module and leave the other end of the
shield unconnected and insulated from earth ground.
3. Never run Signal or Control cables in the same conduit or raceway with AC
power lines, conductors feeding motors, solenoids, SCR controls, and
heaters, etc. The cables should be run through metal conduit that is properly
grounded. This is especially useful in applications where cable runs are long
and portable two-way radios are used in close proximity or if the installation
is near a commercial radio transmitter. Also, Signal or Control cables within
an enclosure should be routed as far away as possible from contactors,
control relays, transformers, and other noisy components.
4. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
5. In extremely high EMI environments, the use of external EMI suppression devices such as Ferrite Suppression Cores for signal and control cables is effective. The following EMI suppression devices (or equivalent) are recommended:
Fair-Rite part number 0443167251 (RLC part number FCOR0000) TDK part number ZCAT3035-1330A Steward part number 28B2029-0A0
6. T o protect relay contacts that control inductive loads and to minimize radiated and conducted noise (EMI), some type of contact protection network is normally installed across the load, the contacts or both. The most effective location is across the load. a. Using a snubber, which is a resistor-capacitor (RC) network or metal oxide
varistor (MOV) across an AC inductive load is very effective at reducing EMI and increasing relay contact life.
b. If a DC inductive load (such as a DC relay coil) is controlled by a transistor
switch, care must be taken not to exceed the breakdown voltage of the transistor when the load is switched. One of the most effective ways is to place a diode across the inductive load. Most RLC products with solid state outputs have internal zener diode protection. However external diode protection at the load is always a good design practice to limit EMI. Although the use of a snubber or varistor could be used.
RLC part numbers: Snubber SNUB0000
Varistor ILS11500 or ILS23000
Note: Reference manufacturer’s instructions when installing any EMI
suppression device.
7. Also care should be taken when connecting input and output devices to the instrument. When a separate input and output common is provided, they should not be mixed. Therefore a sensor common should NOT be connected to an output common. This would cause EMI on the sensitive input common, which could effect the instruments, operation.
Visit RLC’s web site at www.redlion.net for more information on EMI
guidelines, Safety and CE issues as they relate to Red Lion Controls products.
HARDWARE
CSPID1 ONLY ANALOG OUTPUT OPTION
Select either Voltage or Current output by placing the output jumpers in the appropriate location. The output jumpers are located on the side of the CSPID1 module.
CSPID2 ONLY INPUT JUMPERS
Select the desired input type for each channel by positioning the jumper
appropriately. For thermocouple inputs, the jumper position can be ignored.
Current
Voltage
ATTACH THE MODULE BASE TO THE DIN RAIL
ATTACH MODULE TO BASE
INSTALLATION
SEPARATE BASE FROM MODULE
5
WIRING
WIRING CONNECTIONS
All conductors should meet voltage and current ratings for each terminal. Also, cabling should conform to appropriate standards of good installation, local codes and regulations. When wiring the module, use the numbers on the label to identify the position number with the proper function. Strip the wire, leaving approximately 1/4" (6 mm) of bare wire exposed. Insert the wire into the terminal, and tighten.
RTD
Heater Current Monitor
Voltage
CSPID1 INPUT CONNECTIONS
Current
Thermocouple and Millivolt
RTD
Heater Current Monitor
Voltage
CSPID2 INPUT CONNECTIONS
CurrentThermocouple and Millivolt
6
CSPID1 OUTPUT CONNECTIONS
Outputs 1 and 2 - Relay Version
Outputs 1 and 2 - Solid State Version
Output 3
Analog Output
CSPID2 OUTPUT CONNECTIONS
Outputs 1- 4 - Relay Version
Outputs 1- 4 - Solid State Version
Outputs 1- 4 - Triac Version
Outputs 1 and 2 - Triac Version
7
LEDS
STS – STATUS LED
The Status LED is a dual color LED that provides information regarding the state of the module. This includes indication of the various stages of the start-up routine (power-up), as well as any errors that may occur.
Startup Routine
FIRMWARE UPGRADE
The module’s firmware is stored in flash memory to prevent software/hardware conflicts, and so that software features may be added in the future.
During a download, Crimson compares its own library of firmware files with those stored in the Master module. If they do not match, Crimson will download the necessary files. The Master then checks to make sure that the I/O modules contain the same firmware. If they contain a different revision, the Master will automatically copy those files into the module's flash memory. During this process, the module LEDs will flash rapidly, starting with the top row, and progressing through the remaining rows until the process is complete.
Error States
OP1, OP2, OP3, OP4* – OUTPUT STATUS LED
The OP1, OP2, OP3, and OP4* LEDs are factory configured to indicate the
status of the outputs. The LEDs turn on when the output is active.
These LEDs may be remapped to various other module properties. *CSPID2 only
ALM OR AL1 & AL2 – ALARM LED
The Alarm LEDs are factory configured to indicate the presence of an alarm.
Whenever one of the seven alarms is active, the LED turns on.
These LEDs may be remapped to various other module properties.
CONFIGURATION
Programming is done via Crimson® software, a Windows®compatible
configuration interface. Please see the Crimson manual for more information.
Rapidly Flashing Red
Module is currently running the boot loader and/or being flash upgraded by Crimson. This occurs for four seconds during a power up.
Steady Red Module switching to configuration. Green Module performing normally.
Module is controlling properly, but has lost communication with the Master.
Green/Pulsing Red
Module not controlling, and not communicating.Solid Red
ORDERING INFORMATION
Programming Cable for CS, G3, & Paradigm Series
Crimson®Programming Software
2
Communications Cables
1
Crimson®Programming Software, Manual, and Download Cable Rail Stops (Qty 2)
Replacement Base Replacement Termination Plug
CBL
Software
Accessories
CBLPROG0
SFCRM
CBLxxxxx
SFCRK RSRSTP00 CSBASE00 CSTERM00
Single Loop Module, Solid State Outputs, Heater Current Input
Dual Loop Module, Triac Outputs, Heater Current Input
CSPID1SM
CSPID2TM
Single Loop Module, Solid State Outputs, Analog Output
Dual Loop Module, Triac Outputs
CSPID1SA
CSPID2T0
Single Loop Module, Solid State Outputs
Dual Loop Module, Solid State Outputs, Heater Current Input
CSPID1S0
CSPID2SM
Single Loop Module, Relay Outputs, Heater Current Input
Dual Loop Module, Solid State Outputs
CSPID1RM
CSPID2S0
Single Loop Module, Relay Outputs, Analog Output
Dual Loop Module, Relay Outputs, Heater Current Input
CSPID1RA
CSPID2RM
Single Loop Module, Triac Outputs, Analog Output
Single Loop Module, Relay Outputs
Dual Loop Module, Relay Outputs
CSPID1
1
CSPID2
PID Control Modules CSPID1TA
CSPID1R0
CSPID2R0
Modular Controller Master, Multi Comms ports and Ethernet
CSMSTRMaster Module
CSMSTRGT
CSMSTRLE
CSMSTRSX
CSMSTRV2
DESCRIPTIONMODEL NO.TYPE PART NUMBER
Communications
Cables
(10 feet)
1
Visit www.redlion.net for a complete list of PID modules, data acquisition modules, communications drivers and cables.
2
Free at www.redlion.net
Modular Controller Master with multiple protocol converter, data logger, web server with Virtual HMI up to VGA(640 x 480) size and expansion slot with increased SDRAM
Modular Controller Master with multiple protocol converter, Ethernet and expansion slot
Modular Controller Master with multiple protocol converter, data logger, web server with Virtual HMI up to QVGA(320 x 240) size and expansion slot.
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option. The Company disclaims all liability for any affirmation, promise or representation with respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries, deaths, property damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be to any extent liable, including without limitation penalties imposed by the Consumer Product Safety Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter.
No warranties expressed or implied are created with respect to The Company’s products except those expressly contained herein. The Customer acknowledges the disclaimers and limitations contained herein and relies on no other warranties or affirmations.
Red Lion Controls Headquarters 20 Willow Springs Circle York PA 17406 Tel +1 (717) 767-6511 Fax +1 (717) 764-0839
Red Lion Controls
China
Unit 101, XinAn Plaza
Building 13, No.99 Tianzhou Road
ShangHai, P.R. China 200223
Tel +86 21 6113-3688
Fax +86 21 6113-3683
Red Lion Controls
Europe
Printerweg 10
NL - 3821 AD Amersfoort
Tel +31 (0) 334 723 225
Fax +31 (0) 334 893 793
Red Lion Controls
India
54, Vishvas Tenement
GST Road, New Ranip,
Ahmedabad-382480 Gujarat, India
Tel +91 987 954 0503
Fax +91 79 275 31 350
Re-Order from
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1-888-55-66342
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